U.S. patent number 11,027,298 [Application Number 14/073,835] was granted by the patent office on 2021-06-08 for systems and methods to precisely control output pressure in buffered sprayers (duo1).
This patent grant is currently assigned to Dispensing Technologies B.V.. The grantee listed for this patent is DISPENSING TECHNOLOGIES B.V.. Invention is credited to Aaron Haleva, Wilhelmus Johannes Joseph Maas, Paulo Nervo, Dominicus Jan van Wijk, Petrus Lambertus Wilhelmus Hurkmans.
United States Patent |
11,027,298 |
Maas , et al. |
June 8, 2021 |
Systems and methods to precisely control output pressure in
buffered sprayers (DuO1)
Abstract
Dispensing devices can include buffers. This obviates the need
for continually pumping the device to dispense spray or foam. A
buffer can be spring loaded, spring loaded combination, elastomeric
or gas, and can be in line or adjacent to a piston chamber. Such
sprayers and foamers can be mounted upside down. With a buffer, a
piston chamber can deliver a greater amount of liquid per unit time
than can be dispensed through the nozzle(s). The fraction of liquid
that cannot be dispensed can be sent to the buffer for dispensing
after the piston downstroke has completed. Volume of the piston
chamber and buffer, pressure response of the buffer, throughput of
the nozzle, and the minimum opening pressure of the outlet valve
can be arranged to restrict the outlet pressures of liquid droplets
exiting the nozzle within a defined range.
Inventors: |
Maas; Wilhelmus Johannes Joseph
(Someren, NL), van Wijk; Dominicus Jan (Helmond,
NL), Nervo; Paulo (Duizel, NL), Wilhelmus
Hurkmans; Petrus Lambertus (Someren, NL), Haleva;
Aaron (Oakhurst, NJ) |
Applicant: |
Name |
City |
State |
Country |
Type |
DISPENSING TECHNOLOGIES B.V. |
Helmond |
N/A |
NL |
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Assignee: |
Dispensing Technologies B.V.
(Helmond, NL)
|
Family
ID: |
1000005601981 |
Appl.
No.: |
14/073,835 |
Filed: |
November 6, 2013 |
Prior Publication Data
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Document
Identifier |
Publication Date |
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US 20140246506 A1 |
Sep 4, 2014 |
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Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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61723045 |
Nov 6, 2012 |
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61805044 |
Mar 25, 2013 |
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61810697 |
Apr 10, 2013 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B05B
11/3038 (20130101); B29C 65/18 (20130101); B29C
66/0342 (20130101); B29C 66/4312 (20130101); B29C
66/8322 (20130101); B29C 66/81419 (20130101); B29C
66/439 (20130101); B29C 66/83221 (20130101); B05B
11/0075 (20130101); B29C 65/7802 (20130101); B29C
66/72341 (20130101); B05B 11/0032 (20130101); B29C
66/1122 (20130101); B05B 11/3073 (20130101); B05B
11/3076 (20130101); B05B 11/3098 (20130101); B29C
66/0014 (20130101); B29C 66/53262 (20130101); B29C
66/849 (20130101); B29C 65/7841 (20130101); B05B
11/3077 (20130101); A47L 11/4088 (20130101); B29C
66/81815 (20130101); B29C 65/743 (20130101); B29C
66/43121 (20130101); B29C 66/81465 (20130101); A47L
13/22 (20130101); B05B 11/3011 (20130101); B05B
9/0883 (20130101); B05B 11/3074 (20130101); B05B
15/62 (20180201); B29C 65/48 (20130101); B29C
66/71 (20130101); B29C 65/08 (20130101); B29C
65/16 (20130101); B29C 66/71 (20130101); B29K
2023/06 (20130101); B29C 66/71 (20130101); B29K
2023/12 (20130101); B29C 66/71 (20130101); B29K
2067/00 (20130101); B29C 66/71 (20130101); B29K
2077/00 (20130101); B29C 66/71 (20130101); B29K
2083/00 (20130101) |
Current International
Class: |
B05B
11/00 (20060101); B05B 9/08 (20060101); B29C
65/18 (20060101); B29C 65/00 (20060101); B29C
65/78 (20060101); B29C 65/74 (20060101); A47L
11/40 (20060101); B05B 15/62 (20180101); A47L
13/22 (20060101); B29C 65/08 (20060101); B29C
65/16 (20060101); B29C 65/48 (20060101) |
Field of
Search: |
;239/333,1
;222/321.8,340,383.1 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
Primary Examiner: Lieuwen; Cody J
Parent Case Text
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of United States Provisional
Patent Application Nos. (i) 61/723,045, entitled NEW GENERATION
SPRAY/FOAM DISPENSERS, WITH AND WITHOUT BUFFERING SYSTEMS ("NGOP"),
filed on Nov. 6, 2012, (ii) 61/805,044, entitled IMPROVEMENTS TO
FLAIROSOL TECHNOLOGY, filed on Mar. 25, 2013, and (iii) 61/810,697,
entitled BUFFER SPRAYER WITH DIRECT ACTION RELEASE ("DU01 PUMP"),
filed on Apr. 13, 2013, the disclosure of each of which is hereby
fully incorporated herein by reference.
Claims
What is claimed is:
1. A liquid dispensing device, comprising: an inlet valve,
configured to receive liquid from a reservoir and pass the liquid
to a piston chamber; a piston and a piston chamber, the piston
chamber emptying into an inlet of a buffer chamber, the buffer
chamber coupled to an outlet path, the outlet path at an opposite
end of the buffer chamber from the inlet; an actuator for
controlling the piston; a compressible gas buffer provided in the
buffer chamber, the compressible gas buffer including a closed
outer surface and a fixed quantity of gas provided within the
closed outer surface, the compressible gas buffer having an initial
uncompressed volume; an outlet valve having a defined minimum
opening pressure, the outlet valve provided between the buffer
chamber and the outlet path; and a nozzle with a defined throughput
in fluid communication with the outlet path.
2. The liquid dispensing device of claim 1, wherein, the volume of
the piston chamber, the volume of the buffer, a pressure response
of the buffer, the defined throughput of the nozzle, and the
defined minimum opening pressure of the outlet valve are further
arranged to allow for dispensing of the liquid between piston
downstrokes.
3. The liquid dispensing device of claim 1, wherein at least one
of: the buffer is in-line with the piston chamber; or there is a
one-way valve connecting the buffer to the piston chamber, such
that fluid cannot move from the buffer back into the piston
chamber.
4. The liquid dispensing device of claim 1, wherein at least one
of: when a user releases the actuator, fluid remaining in the
buffer chamber moves back into the piston chamber, and stops
exiting through the outlet valve; or fluid exiting through the
outlet valve begins to taper off immediately upon the user
releasing the actuator.
5. The liquid dispensing device of claim 1 further comprising at
least one bypass channel provided in the buffer chamber, the at
least one bypass channel including a groove on an inner surface of
the buffer chamber, wherein the fluid flow path in the at least one
bypass channel is along a direction parallel to at least one of a
longitudinal axis of the buffer or a longitudinal axis of the
buffer chamber.
6. The liquid dispensing device of claim 1, wherein the piston and
piston chamber are at least one of: separate components, an
integrated component, or comprise a stretched piston.
7. The liquid dispensing device of claim 1, wherein the outlet
valve is one of a dome valve, a dome valve reinforced with a
spring, and a plastic binary dome valve.
8. The liquid dispensing device of claim 1, wherein the liquid
dispensing device is configured to dispense a spray, a foam or
either a spray or a foam.
9. The liquid dispensing device of claim 1, further comprising a
product container, in fluid communication with the inlet valve,
wherein the product container is a container within a container
bottle.
10. The liquid dispensing device of claim 1, wherein the volume of
the buffer chamber is equal to or greater than the volume of the
piston chamber by a factor of between 1.0 and 5.
11. The liquid dispensing device of claim 1, wherein one or more of
the volume of the piston chamber, the volume of the buffer chamber,
the uncompressed volume of the buffer, a pressure response of the
buffer, the defined throughput of the nozzle, and the defined
minimum opening pressure of the outlet valve, are co-operatively
arranged to allow for dispensing of the liquid between piston
downstrokes, and following the dispensing of liquid from the piston
chamber to the nozzle, a quantity of fluid is dispensed from the
buffer chamber to and out the nozzle.
12. The liquid dispensing device of claim 1, wherein, at least one
of: in a liquid intake operation, a fluid is drawn from a container
into the piston chamber, and in a dispensing operation a portion of
the fluid is sent from the piston chamber towards the nozzle, and a
remainder of the fluid is sent to the buffer chamber; there is a
one-way valve connecting the buffer chamber to the piston chamber,
such that fluid cannot move from the buffer chamber back into the
piston chamber; and once a user releases a trigger, fluid flowing
from the buffer chamber out through the outlet valve stops.
13. A liquid dispensing device, comprising: an inlet valve,
configured to receive liquid from a reservoir and pass the liquid
to a piston chamber; a piston and a piston chamber, the piston
chamber emptying into an inlet of a buffer chamber, the buffer
chamber coupled to an outlet path, the outlet path at an opposite
end of the buffer chamber from the inlet; an actuator for
controlling the piston; a compressible gas buffer entirely disposed
within the buffer chamber, the compressible gas buffer including a
closed outer surface and a fixed quantity of gas provided within
the closed outer surface, the compressible gas buffer having an
initial uncompressed volume; an outlet valve having a defined
minimum opening pressure, the outlet valve provided between the
buffer chamber and the outlet path; and a nozzle with a defined
throughput in fluid communication with the outlet path, wherein
fluid in excess of the defined throughput is stored in the buffer
chamber by compressing a volume of the buffer.
14. The liquid dispensing device of claim 13, wherein the defined
minimum opening pressure of the outlet valve is P1, and a minimum
pressure to compress the gas buffer is P2 and wherein P2 is greater
than or equal to P1.
15. The liquid dispensing device of claim 14, wherein the defined
throughput of the nozzle is less than a output of the piston
chamber, and, as a result, fluid exiting the piston chamber
increases in pressure to a value greater than or equal to P2.
16. The liquid dispensing device of claim 15, wherein when fluid
exiting the piston chamber is at a pressure greater than or equal
to P2, fluid both exits the nozzle and is stored in the buffer
chamber by compressing the buffer to a smaller volume than the
initial volume.
17. The liquid dispensing device of claim 13, wherein the outlet
channel is integrated with the buffer chamber.
18. The liquid dispensing device of claim 17, wherein the outlet
channel includes at least one groove provided on an inner surface
of the buffer chamber, the at least one groove defining a fluid
flow path from the outlet of the piston chamber adjacent to the
buffer when the buffer has its initial uncompressed volume, to the
outlet of the buffer chamber.
19. The liquid dispensing device of claim 13, wherein the device is
further configured such that at least one of: when a user releases
the actuator, fluid remaining in the buffer chamber moves back into
the piston chamber, and does not exit through the outlet valve;
fluid flow exiting through the outlet valve begins to taper off
immediately upon the user releasing the actuator; or the fluid flow
path in each groove is along a direction parallel to at least one
of a longitudinal axis of the buffer or a longitudinal axis of the
buffer chamber.
20. The liquid dispensing device of claim 13, wherein one or more
of the volume of the piston chamber, the volume of the buffer
chamber, the initial uncompressed volume of the buffer, a pressure
response of the buffer, the defined throughput of the nozzle, and
the defined minimum opening pressure of the outlet valve, are
co-operatively arranged to allow for dispensing of the liquid
between piston downstrokes, and following the dispensing of liquid
from the piston chamber to the nozzle, a quantity of fluid is
dispensed from the buffer chamber to and out the nozzle.
Description
TECHNICAL FIELD
The present invention relates to dispensing technologies, and in
particular to improved sprayers/foam dispensers of various types,
wherein output pressure, and thus droplet size, can be precisely
controlled.
BACKGROUND OF THE INVENTION
Liquid dispensing devices such as spray bottles are well known.
Some offer pre-compression so as to insure a strong spray when the
trigger is pulled and prevent leakage. Sprayers and foamers can be
easily manufactured and filled, and are often used to dispense
cleaners of all types, for example. However, in many circumstances
it is preferred not to have to continually pump a dispensing device
to push out the dispensed liquid. Rather, it would be much more
convenient to be able to continue the spray or foam substantially
past the user pulling a trigger or otherwise actuating the sprayer
head. For example, if by actuating a sprayer head a certain
reasonable number of times per minute a continuous spray could be
obtained, many users would find that optimal.
One set of dispensing devices that provide a continuous spray are
aerosol dispensers, such as are used for cooking spray (e.g.,
Pam.RTM.), insect spray (e.g., Raid.RTM.), lubricants (e.g.,
WD-40.RTM.), and a host of other uses. Aerosols hold a liquid or
other dispensate under pressure such that when a user activates the
device (e.g., by pressing a button) the pressurized contents are
allowed to escape. However, aerosols present both significant
environmental hazards as well as packaging drawbacks, which result
from the necessity of using an aerosol propellant in them, and the
further necessity of pressurizing them. This requires filling such
devices under pressure, using packaging strong enough to withstand
the pressure, and taking steps to insure that the propellant
maintains a uniform pressure over the life of the can or container.
Such conditions often require use of non-environmentally friendly
materials and ingredients.
Additionally, conventional aerosols do not continue spraying unless
the user keeps their finger on the button. Inasmuch as people
generally push on the aerosol can with the index finger of their
dominant hand, this requirement precludes their ability to do
anything with the spray or the surface/object on which the spray is
directed with that hand making it difficult to clean, etc. Thus,
users are forced to spray, for example, a cleaner on a surface,
then stop spraying, then wipe or scrub, etc. Recently floor
cleaning products have emerged to replace mops. Many try to spray a
cleaning fluid or floor care product from one or more nozzles while
a user is pushing the device along the floor or surface. Some of
these devices utilize a motorized pump, run by a power cord or
battery. However, such devices are often not robust, and do not
last long. Or, for example, in the case of battery powered floor
cleaners, any serious current draw requires large batteries, and
frequent changing of same, which is both environmentally
unfriendly, cumbersome and expensive.
Finally, although conventional pre-compression sprayers control the
minimum output pressure, they do not control in any way the maximum
output pressure. A conventional sprayer starts dispensing at a low
pressure. During a trigger stroke, the pressure rises up to a peak
pressure. The liquid is forced through an orifice, but only a part
of the liquid can pass the nozzle, so the pressure will build up
within the sprayer. Towards the end of the stroke, the liquid
pressure drops to zero. The low pressure at the beginning and end
of the stroke thus creates larger, non-uniform droplets at the
right and left sides of the conventional sprayer pressure time
curve. A pre-compression sprayer starts spraying when the liquid
pressure is at a pre-determined pressure. This pre-determined
pressure is known as the "cracking pressure" of the outlet valve.
During the trigger stroke the pressure rises up to a peak pressure.
When the pressure drops to a predetermined pressure (closing
pressure of the outlet valve) dispensing stops immediately. The
droplet size at the beginning and end of a dispensing stroke in a
pre-compression sprayer are smaller because the pressure is higher.
The peak pressure, creating even smaller droplets is also higher
than that of a conventional sprayer, because the same amount of
liquid is dispensed in a shorter time. Therefore more pressure
builds up. Thus, relative to a conventional sprayer the pressure
difference across the pressure time curve will still be there and
even be greater. It is only shifted to a higher pressure range.
Thus, difficulties with standard pre-compression sprayers include,
for example, (1) wider spreading droplet sizes, and (2) too small
droplet sizes.
To overcome these drawbacks, what is needed in the art is a
sprayer/foamer device that can provide elongated spray or
continuous spray, where a user does not need to continually pump or
actuate, thus leaving the user's hands free to work between strokes
(continuous spray), or following a stroke (elongated spray), but
where output pressure is controlled to be within a specific
pressure range.
What is further needed in the art is the adaptation of such
functionality to floor cleaning systems, large surface cleaning
systems, bathroom and toilet cleaning systems, and the like.
SUMMARY OF THE INVENTION
In exemplary embodiments of the present invention, various novel
dispensing devices can be provided. Such devices can involve a
range of sprayer heads and sprayer/foamer systems incorporating
such heads. Novel sprayer/foamer heads can include buffers of
various types. By using a buffer, a user need not continually be
pumping the device in order for the device to be spraying or
foaming. In exemplary embodiments of the present invention, such a
buffer can be spring loaded, spring loaded combination, elastomeric
or gas. In exemplary embodiments of the present invention, the
buffer can be in line or adjacent to a piston chamber. If adjacent,
it can be connected to the piston chamber with a one way valve, to
provide for spray after a downstroke of the piston has been
completed, or without, to allow spraying to cease once a user
releases the trigger or other actuator. In exemplary embodiments of
the present invention, such novel sprayers and foamers can be
mounted upside down, in various "Flairomop" devices, used to clean
floors or the like. When using a buffer, a piston chamber can be
designed to deliver greater amount of liquid per unit time than can
be possibly dispensed through the nozzle or nozzles. The fraction
of liquid that cannot be sent through the nozzle(s), due to their
inherent restriction, can thus be sent to the buffer for dispensing
after the piston downstroke has been completed. A volume of the
piston chamber, a volume of the buffer, a pressure response of the
buffer, the throughput of the nozzle, and the minimum opening
pressure of the outlet valve can be arranged to restrict the outlet
pressures of liquid droplets exiting the nozzle within a defined
range.
BRIEF DESCRIPTION OF DRAWINGS
The patent or application file contains at least one drawing
executed in color. Copies of this patent or patent application
publication with color drawing(s) will be provided by the Office
upon request and payment of the necessary fee.
FIGS. 1-3 illustrate pre-compression and the problems with
conventional pre-compression sprayers;
FIGS. 4-5 illustrate a novel combination of pre-compression and
control of maximum pressure according to exemplary embodiments of
the present invention;
FIG. 6 illustrates correlation of various sprayer elements to
control output pressure in a defined band according to exemplary
embodiments of the present invention;
FIGS. 7-8 illustrate high and low output pressure bands,
respectively;
FIG. 9 provides various exemplary combinations of sprayer
parameters used to control output pressure according to exemplary
embodiments of the present invention;
FIGS. 10-11 depict various pre-compression technologies that can be
used in exemplary embodiments of the present invention;
FIGS. 12, 13A, 13B, 14A, 14B, 15A and 15B describe various buffers
that can be used in exemplary embodiments of the present
invention;
FIGS. 16A, 16B, 16C, 17A, 17B and 17C depict the various
functionalities sprayer engines can have in exemplary embodiments
of the present invention;
FIGS. 18A, 18B, 18C, 18D, 19A, 19B, 19C, 19D, 19E, 20A and 20B,
depict various lock out systems according to exemplary embodiments
of the present invention;
FIGS. 18E, 18F and 18G illustrate exemplary key parameters that can
be varied to create user specific lock out keys;
FIGS. 21-33 illustrate an exemplary "Flairosol D'Lite" sprayer
according to exemplary embodiments of the present invention;
FIGS. 34-40, next described, illustrate various technological
advances of the exemplary Flairosol D'Lite type sprayer;
FIG. 40 illustrates the use of a novel all plastic binary dome
valve according to exemplary embodiments of the present
invention;
FIGS. 41-47 present details of the novel dome valve of FIG. 40;
FIGS. 48-52 illustrate exemplary gas buffers that can be used in
exemplary embodiments of the present invention;
FIGS. 53-65 illustrate exemplary manufacturing techniques for gas
buffers;
FIGS. 66-67 illustrate an alternate manufacturing technique for gas
buffers;
FIG. 68 shows how multiple pumps can be used with common inlet line
and a common outlet or output line to increase output, according to
exemplary embodiments of the present invention;
FIG. 69 presents an exemplary "Flairomop" device and exemplary
nozzle positions thereof according to exemplary embodiments of the
present invention;
FIG. 70 presents the general properties of a Flairomop device
according to exemplary embodiments of the present invention;
FIGS. 71 through 74 illustrate details of producing a high pressure
continuous spray for a Flairomop device according to exemplary
embodiments of the present invention;
FIG. 75 illustrates an exemplary Flairomop device operating under
high pressure with direct action according to exemplary embodiments
of the present invention;
FIG. 76 provides operational details of the exemplary Flairomop
high pressure direct action device presented in FIG. 75;
FIG. 77 presents an exemplary Flairomop operative at low pressure
device according to exemplary embodiments of the present
invention;
FIG. 78 illustrates further operational details of the Flairomop
low pressure device presented in FIG. 77; and
FIGS. 79-85 depict an exemplary continuous stop engine;
FIGS. 86-90 depict an improvement thereto;
FIGS. 91-92 depict a further improvement thereto; and
FIGS. 93-97 depict exemplary DuO1 sprayers with buffers not in-line
with the piston bore, of various types.
DETAILED DESCRIPTION OF THE INVENTION
In exemplary embodiments of the present invention, various novel
sprayers and related dispensing devices are presented. The sprayer
heads shown can, in general, work with both standard bottles or
reservoirs as well as the "bag within a bag" or "container within a
container" Flair.RTM. technology developed and provided by
Dispensing Technologies B.V. of Helmond, The Netherlands. The "bag
within a bag" Flair.RTM. technology, which causes the inner
container to shrink around the product, thus obviates headspace or
air bubbles in the inner container. Because in Flair.RTM.
technology the pressure applied to the inner bag results from a
pressurizing medium, often atmospheric pressure vented between said
inner and outer containers, venting of the liquid container is not
required. Of course, whenever a product is dispensed from an inner
bag in a Flair system, which shrinks to the remaining volume of the
product as it dispenses, then the pressure has to be equalized in
the gap between the outer container and the inner container. This
can be done, for example, using a medium, such as, for example,
air, whether at atmospheric pressure or higher. This can easily be
done by venting the gap to ambient air somewhere between the inner
container and the outer container. This can be done, for example,
by providing a vent, such as, for example, on the bottom of the
Flair container, or at any other convenient position of the outer
container. In some exemplary embodiments such a vent is moved to
the sprayer head itself, via a novel outlet valve.
FIGS. 1 through 4, next described, illustrate the relationship
between output pressure and time of the outflow of various types of
sprayers. With reference to FIG. 1, the left-most image shows the
pressure time curve of a conventional sprayer. There is a
distribution of pressures, essentially a Gaussian curve, and with
greater pressure there is a smaller droplet size. Thus, in the
pressure curve of conventional sprayer there is a distribution of
droplet sizes. A conventional sprayer has no closed valves. When
the piston is actuated the sprayer immediately starts dispensing.
Thus, slow actuation of the pump by a user results in large
droplets or drips and the liquid pressure is low. On the other
hand, fast actuating of the piston can decrease the amount of large
droplets because the pressure then rises more quickly towards the
peak pressure. Thus, in a conventional sprayer performance is
highly dependent upon the user operating or the behavior of the
user operating the sprayer. The middle image of FIG. 1 is the
pressure curve of a pre-compression sprayer. Notably there is a
larger range of pressures that are output from a pre-compression
sprayer. A pre-compression sprayer has normally closed valves. The
outlet valve therefore only opens at a pre-determined pressure. The
displacement volume between inlet and outlet valve of the pump is
to become zero during a compression stroke. If it does not, the
pump cannot prime. When the piston is actuated by a user the
sprayer only starts dispensing when the liquid pressure is above
the cracking pressure of the outlet valve. Therefore slow actuation
of the pump will give no drips because the pump starts dispensing
at a higher pressure. Here in a pre-compression sprayer performance
is less dependent upon the user's operating behavior than in the
case of a conventional sprayer.
The right-most image of FIG. 1 illustrates the pressure time curve
of a sprayer according to exemplary embodiments of the present
invention. It is noted that on occasion the inventive sprayers
described herein will be referred to as "DuO1" sprayers. A DuO1
dispenser has normally closed valves just as in the case of a
pre-compression sprayer. Therefore the outlet valve only opens at a
pre-determined pressure. There is also a buffer, however. The
buffer immediately stores the overflow of liquid, thus preventing
peak pressures. The DuO1 synchronized components determine the
output performance. Fast or slow triggering by a user has little
effect on the output, because the pressures are equalized through
buffering. The performance of a DuO1 dispenser is very little
dependent upon the operating behavior of the user. As noted in the
right-most image of FIG. 1 there is a much-narrower range of output
pressures because peak pressures are topped off by buffering the
overflow and thus the pressures at the top of the pre-compression
sprayer pressure curve are cut off at the maximum pressure which is
the uppermost line in FIG. 1, right-most image. By buffering the
overflow this reduces the pressure range/droplet size spread. And
thus for a DuO1 sprayer, output pressure runs in a narrow band
between the minimum pressure, that of the pre-compression valve,
and the maximum pressure, which is a function of the pressure
generated by the buffer during continuous strokes or during one
single stroke in case of a direct stop embodiment (as described
below). Various DuO1 synchronized components determine the output
performance. Fast or slow triggering has little effect on the
output, because the pressures are equalized through buffering.
Output pressure tends to be at the buffer pressure.
FIG. 2, next described, provides further details of a
pre-compression sprayer. As noted with reference to FIG. 1 a
conventional sprayer starts dispensing at a low pressure. During a
trigger stroke, the pressure rises up to a peak pressure. The
liquid is forced through an orifice, but only a part of the liquid
can pass the nozzle, so the pressure will build up within the
sprayer. Towards the end of the stroke, the liquid pressure drops
to zero. The low pressure at the beginning and end of the stroke
thus creates larger, non-uniform droplets as shown at the right and
left sides of the conventional sprayer pressure time curve shown in
FIG. 2. A pre-compression sprayer starts spraying when the liquid
pressure is at a pre-determined pressure. This pre-determined
pressure is known as the "cracking pressure" of the outlet valve.
During the trigger stroke the pressure rises up to a peak pressure.
When the pressure drops to a predetermined pressure (closing
pressure of the outlet valve) dispensing stops immediately. The
droplet size at the beginning and end of a dispensing stroke in a
pre-compression sprayer are smaller because the pressure is higher.
The peak pressure, creating even smaller droplets is also higher
than that of a conventional sprayer as shown in FIG. 2, because the
same amount of liquid is dispensed in a shorter time. Therefore
more pressure builds up. Thus, relative to a conventional sprayer
the pressure difference across the pressure time curve will still
be there and even be greater. It is only shifted to a higher
pressure range.
Thus, a conventional sprayer starts dispensing at a low pressure,
and during a trigger stroke the pressure rises up to a peak
pressure. The liquid is forced through an orifice, but only a part
of the liquid can pass through the nozzle, so pressure will build
up. Towards the end of the stroke the liquid pressure drops to
zero. The low pressure seen at the beginning and the end of the
stroke creates larger non uniform droplets.
A pre-compression sprayer starts spraying when the liquid pressure
is at a pre-determined pressure (the cracking pressure of the
outlet valve). During a trigger stroke the pressure rises up to a
peak pressure. When the pressure drops to a predetermined pressure
(closing pressure of the outlet valve), dispensing stops
immediately.
The droplet sizes at the start and end of the dispensing stroke are
smaller, because the pressure is then higher. The peak pressure
(creating even smaller droplets) is higher than in a conventional
sprayer because the same amount of liquid is dispensed in a shorter
time. (more pressure build up). Compared to a conventional sprayer
the pressure difference will still be there, or be even larger. It
only shifted to an higher pressure level
Issues with pre-compression sprayer: (1) a wider spread in droplet
sizes, and (2) too small droplets sizes due to very high peak
pressure, as shown.
FIG. 3 illustrates the difficulties with standard pre-compression
sprayers. These include, for example, (1) wider spreading droplet
sizes, and (2) too small droplet sizes. For many liquids a wider
spread of droplet sizes is not a problem. Sometimes, however, the
range of droplet sizes is required to be smaller in order to have
better performance of the liquid, such as, for example to create a
foam. Too small droplet sizes (less than or equal to 10 microns)
can cause a health hazard when they are of such a size that can be
inhaled and wherein the liquid can be dangerous, such as, for
example when using bleach contained liquids. Also, too small
droplet sizes can stray off when dispensed and not hit the target.
Rather they can land on a non-intended surface which they can
damage. For example a hard surface cleaner which causes stains when
it lands on a fabric. These processes are illustrated at the bottom
of FIG. 3. Additionally, as shown, in a foamer context, screen is
sized for a particular droplet size which would hit its grid and
thus become foam. Too small droplets do not hit the foaming screen,
and thus pass through without making foam, can stray off, be
inhaled, and fail to land on an intended target. On the other hand,
too large droplets are held back by the foamer screen, and drop
down, also not reaching the target. FIGS. 4 and 5, as do the
rightmost image of FIG. 1, illustrate a solution to the
above-described problems with standard pre-compression
sprayers.
As shown in FIG. 4, DuO1 technology avoids the issues which evolve
when using a pre-compression sprayer. To do so, it avoids the
pressure peaks which cause the droplet sizes to be too small, and
makes the range of droplet sizes smaller. In other words the
pressure range in which the dispenser operates needs to be made
smaller.
DuO1 technology does this because the amount of liquid displaced by
the pump which cannot leave the nozzle within a given dispense time
causes pressure peaks. This overflow of liquid needs to be
temporarily stored. DuO1 stores this liquid within a buffer. The
pressure peak is then avoided and makes the pressure range
smaller.
When no more liquid is displaced by the pump, the buffer releases*
the stored liquid. The buffer releases the liquid either through
the nozzle (continuous or prolonged output) or by return to the
piston chamber or container (direct stop). By coordinating the
components of the DuO1 technology, a tailor fit dispenser can be
created to fit any specified performance requirements.
A DuO1 technology equipped dispenser includes at least: a pump
engine (stroke volume/absolute flow at a certain stroke rate); a
pre-compression outlet valve (opening/closing pressure); an
orifice/nozzle (performance at a certain flow); and a buffer
(overflow storage capacity, overflow storage pressure).
It is desired to avoid the issues which come about when using a
standard pre-compression sprayer. In order to do so it is necessary
to avoid the pressure peaks at the top of a down stroke cycle which
cause the droplet sizes to be too small. Therefore we need to make
the range of droplet sizes smaller. In other words, the pressure
range in which the dispenser operates needs to be narrowed. In
exemplary embodiments of the present invention this is done as
follows. The amount of liquid displaced by the pump which cannot
leave the nozzle within the given dispense time, causes the
pressure peaks. This overflow of liquid needs to be temporarily
stored. This liquid can be stored within a buffer in exemplary
embodiments of the present invention. The pressure peak can then be
avoided and this makes the pressure range smaller. When no more
liquid is displaced by the pump the buffer releases the stored
liquid. The buffer releases the liquid either through the nozzle
(continuous or prolonged output) or returns the liquid to the
piston chamber or container direct stop). The difference between
continuous or prolonged output and direct stop is whether or not a
one-way valve is provided between the buffer and the piston chamber
or not. If the valve is provided then liquid cannot leave the
buffer in a backwards direction running back to the piston chamber
and therefore the sprayer exhibits continuous prolonged output. If
there is no such one way valve any liquid remaining in the buffer
can return to the piston chamber and be used in the next
downspout.
By synchronizing, or coordinating, the components of an exemplary
DuO1 sprayer a dispenser can be created that is tailor-made to fit
the performance requirements of any user or customer. The narrow
output range and concomitant droplet size range that is possible
with an inventive DuO1 sprayer is illustrated in FIG. 4.
Therefore in exemplary embodiments of the present invention, a DuO1
equipped dispenser includes at least a pump engine (stroke
volume/absolute flow at a certain stroke rate), a pre-compression
outlet valve (opening/closing pressure), an orifice/nozzle
(performance at a certain flow) and a buffer (overflow storage
capacity, overflow storage pressure).
FIG. 5 illustrates further details of the correlations between
elements of an exemplary DuO1 sprayer. The opening pressure of the
outlet, responsible for the larger droplet sizes and the maximum
dispensing pressure, responsible for the smaller droplet sizes, are
the controls which can be used to set the limits of the pressure
range/droplet size spread. The right side of FIG. 5 illustrates a
desired pressure level/droplet size which can be provided by a
specification or by a user or by a customer. Given the desired
pressure level/droplet size in exemplary embodiments of the present
invention, a DuO1 sprayer can be created which outputs a range of
pressures or droplet sizes centered on the desired pressure size
and running from {p minus delta p} and {p plus delta p}. The minus
delta p is the opening pressure of the outlet valve and the p plus
delta p is the maximum dispensing pressure at a certain stroke
rate.
When a desired pressure level/droplet size and a range (limits) is
given, the DuO1 technology enables this to be achieved by setting
the controls mentioned above. When a desired pressure level/droplet
size and a range is given in exemplary embodiments of the present
invention DuO1 technology and it allows this to be achieved by
setting the controls mentioned above. As noted above, output
pressure tends to be at the buffer pressure.
FIG. 6 illustrates the various elements of a DuO1 sprayer which
need to be correlated to provide the desired pressure range
illustrated in FIG. 5. With reference to FIG. 6 there is a pump, a
dome valve, a buffer, and an outlet orifice. The maximum dispensing
pressure is a function of the flow of the pump at a certain stroke
rate, the flow at which the orifice/nozzle performs, and the
capacity and pressure of the buffer. The opening and closing
pressure of the pre-compression outlet valve, is, in exemplary
embodiments of the present invention, always set lower than the
default buffer pressure. The default buffer pressure of the buffer
gives all liquid stored in the flow needed for the orifice/nozzle
to perform. The flow of the pump at a certain stroke rate will
always be greater than the flow at which the orifice nozzle
performs. This ensures that there will be an overage of liquid in
every down stroke which cannot possibly be handled by the
throughput of the office or nozzle. The difference between the flow
of the pump at a certain stroke rate and the flow at which the
orifice/nozzle performs is the overflow and the overflow and the
overflow is the excess liquid that can be delivered between
strokes. Therefore the capacity of the buffer should be greater
than or equal to the overflow such that the buffer can always take
up the overflow and then allow it to be released later. If the
buffer could not take up the entire overflow in its capacity
pressure would rise and the situation seen in the standard
pre-compression valve would occur in that higher pressures and
smaller droplet sizes at the peak of a down stroke would ensue. The
maximum dispensing pressure multiplied by the surface area of the
piston or diameter multiplied by the trigger torque equals the
operating force. When peak pressures exist in a system (unlike the
DuO1 system described herein) the trigger force required to be
supplied by a user is thus higher when such peak pressures prevail
in a sprayer. Thus, it takes more force to continue the spraying
operation in such sprayers. This is in contrast to the DuO1 systems
described herein, where buffering eliminates the peak pressures,
and the system operates most of the time at an essentially constant
lower pressure (i.e., the upper horizontal line in FIG. 5--maximum
dispensing pressure).
Thus, in a sprayer of the type shown FIG. 6, the maximum dispensing
pressure is correlated to:
The flow of the pump at a certain stroke rate,
The flow at which the orifice/nozzle performs, and
The capacity and pressure of the buffer.
Opening and closing pressure of the pre-compression outlet valve
< The default buffer pressure. The default buffer pressure of
the buffer gives all liquid stored the flow needed for the
orifice/nozzle to perform.
The flow of the pump at a certain stroke rate > The flow at
which the orifice/nozzle performs, creating overflow. The
difference between the flow of the pump at a certain stroke rate
and the flow at which the orifice/nozzle performs, (which is the
overflow) .gtoreq. than that which the orifice needs to perform in
between strokes of the before mentioned stroke rate
The capacity of the buffer .gtoreq. The overflow
The (maximum dispensing pressure).times.(Surface area of piston
bore diameter).times.(Trigger torque)=Operating force.
FIGS. 7-9 illustrate further details of correlation of various
elements within an exemplary DuO1 sprayer. With reference to FIG.
7, superimposed on a standard pressure time curve is a white band
which is a narrow range of pressures between Pmin and Pmax which
shows a consistent output pressure of a DuO1 sprayer. If smaller
droplets are desired this pressure bandwidth is high as shown in
FIG. 7.
FIG. 7 thus depicts a high pressure bandwidth to create an output
range with smaller droplets. With high pressures a small piston
diameter is needed to maintain an ergonomic operating force. A
maximum possible piston stroke is set to maintain an ergonomic
actuation of the trigger. The (small piston diameter).times.(the
max. piston stroke)=a small displacement volume. The small
displacement volume, having a large flow caused by the high
pressure, requires a nozzle/orifice with a lower flow. So the large
flow, small liquid volume is partially blocked by the low flow
orifice. This overflow is stored in the buffer.
FIG. 8 illustrates a lower bandwidth of output pressure which is a
low pressure bandwidth to create an output range with larger
droplets. Here to achieve this result a low pressure dome and
buffer are used. FIG. 8 thus depicts a low pressure bandwidth to
create an output range with larger droplets. This uses a low
pressure dome and buffer. With low pressures a larger piston
diameter can be used to maintain an ergonomic operating force. A
maximum possible piston stroke is set to maintain an ergonomic
actuation of the trigger. The (larger piston diameter).times.(the
max. piston stroke)=a large displacement volume. The large
displacement volume having a low flow caused by the low pressure,
can use a nozzle/orifice with a larger flow to generate large
droplets. So here the large liquid volume needs to have overflow
with a larger flow nozzle. This overflow is stored in the buffer.
This is essentially the opposite of the situation illustrated in
FIG. 7.
Generalizing from FIGS. 7 and 8 one can easily see that by
manipulating the various parameters of an exemplary DuO1 sprayer
any desired output pressure band whether low, medium or high can be
achieved. FIG. 9 is the table of possible correlation values for
such a range of pressure bands and providing example uses for such
pressure bands and example liquids It is noted that the frequency
for continuous spray is the number of strokes per minute to have an
output in between strokes. And the spray duration single stroke is
the time between the start and stopping of dispensing when a user
makes one stroke and holds the trigger for prolonged spray.
FIG. 10 illustrates various pre-compression technologies which can
be used for the dome valve, or pre-compression valve.
Pre-compression technology can be used in all kind of dispensing
applications. For example Floor mops, Window washers, Sprayers,
etc. Pre-compression technology can be used in a wide
pressure-range of dispensing applications, from low to high
pressures. Pre-compression valves can be made in all kind of types,
configurations and combinations of configurations and materials,
for example, as shown in FIG. 10: (1) All plastic elastic dome
valve with integrated inlet valve; (2) All plastic elastic dome
valve; (3) All plastic Binary dome valve; (4) Spring loaded
membrane valve; and (5) Membrane valve.
Pre-Compression Valves
FIG. 11 illustrates various types of pre-compression valves. With
reference thereto, there is an all plastic elastic dome valve (with
and without integrated inlet valve). Here the closing force of the
valve and therefore the force needed to open the valve is
determined by the elasticity of the material and the pre-tension in
assembly. Additionally, there is a spring loaded membrane valve.
Here the closing force of the valve and therefore the force needed
to open the valve is determined by the force of the metal or
plastic spring placed behind the membrane. The membrane is the seal
between spring and liquid. Finally, there is a membrane valve. Here
the closing force of the valve, and therefore the force needed to
open the valve, is determined by gas pressure behind the membrane.
The gas pressure acts like a spring. The membrane is the seal
between gas and liquid.
Buffers
FIG. 12 illustrates various types of buffers that can be used in
exemplary embodiments of the present invention. With reference
thereto, there is a spring loaded buffer, where the buffer pressure
is set by the properties of the metal spring behind the buffer
piston. The buffering volume is set by the maximum travel of the
buffer piston. Additionally, there is an elastic material buffer,
where the buffer pressure is set by the properties of the buffer;
material, thickness. The buffering volume is set by size of the
elastic part and the buffer housing volume which limits the stretch
of the elastic part. There is a gas loaded buffer, where the buffer
pressure is set by the size of the buffer bag and the pressure of
the gas inside the bag. The buffering volume is set by the size of
the buffer bag. There is a spring loaded membrane buffer, where the
buffer pressure is set by the properties of the metal spring behind
the membrane. The buffering volume is set by the maximum travel of
the membrane. Finally, there is a membrane buffer, where the buffer
pressure is set by gas pressure put behind the membrane. The gas
pressure acts like a spring. The membrane is the seal between gas
and liquid. The buffering volume is set by the maximum travel of
the membrane.
FIG. 13 illustrates assembly and operation of an exemplary elastic
material buffer. With reference to FIG. 13, the elastic buffer is
placed over a core, and liquid is pumped between the buffer and
core. The buffer will thus stretch. Then, liquid is pushed out of
the buffer until the buffer pushes against the core.
FIGS. 14 and 15 illustrate operation of a spring loaded membrane
buffer, and a membrane buffer, respectively. As shown in FIG. 14,
when the piston moves down liquid from piston chamber is pushed via
the buffer towards the nozzle(s). The overflow of liquid which
cannot leave the nozzle(s) is stored in the buffer (01). The buffer
spring compresses and the membrane moves down. When the piston
moves up, the spring pushes up the membrane of the buffer. The
overflow of liquid stored in the buffer is pushed toward the
nozzle(s).
As shown in FIG. 15, when the piston moves down, liquid from piston
chamber is pushed via the buffer towards the nozzle(s). The
overflow of liquid which can not leave the nozzle(s) is stored in
the buffer (01). The gas behind the membrane compresses and the
membrane moves down. When the piston moves up, the gas behind the
membrane pushes up the membrane. The overflow of liquid stored in
the buffer is pushed toward the nozzle(s). It is here noted that
the buffers of FIGS. 14 and 15 are not in line with the piston
chamber.
DuO1 Engines
FIG. 16 illustrates how in exemplary embodiments of the present
invention, various DuO1 engines may be used, including a continuous
stop engine, a continuous spray engine, and one with direct stop
functionality. Cross sections of these engines, and further
details, are provided in FIG. 17.
Thus, for DuO1 Engines:
These engines are based upon the DuO1 platform technology.
They use a buffer to store the overflow of liquid.
Additionally, these engines can be fitted with the OnePak platform
technology.
All DuO1 Engines can be executed in 3 main functionalities: (01)
Direct Stop, (02) Continuous (=Direct Stop+One way valve), and (03)
Continuous-Stop (=Continuous+Release valve).
Within these functions, parameters can be changed to meet custom
requirements. Parameters that may be changed include, for
example:
Output volume (stroke and bore of the piston);
Working pressures (pressure set of buffer and pre-compression
valve, nozzle configuration); and
Spray performances (nozzle configuration).
Lock Out
FIGS. 18-20 illustrate exemplary lock-out systems that can be used
in exemplary embodiments of the present invention. A lock out
system prevents a different supplier's bottle from being used with
a given sprayer head. It also prevents users from refilling a
container supplied with a sprayer with competitor's or imitator's
liquids. Such a lock out system can be controlled and owned by a
sprayer manufacturer, who provides and controls the various "keys"
to open each bottle. In exemplary embodiments of the present
invention, a sprayer manufacturer, provides, owns and controls the
lock-out system. A unique key is given to a customer to protect
against competitors within his own field of use during a licensing
period. The lock out prevents competitors from selling products
compatible with the dispenser, preventing consumers to refill the
bottle with competitor products. The lock out thus acts as an
interface between a bottle and the dispenser.
As noted, the lock out incorporates the inlet valve of the pump
system; this means that the dispenser cannot operate without being
connected to the lock out. The lock-out has unique `key` features,
dedicated to a customer. The geometry of the lock-out can be
changed to create these unique features. For example: the diameter,
depth and added geometries. Thus, in general, the lock out geometry
has to match the interfacing geometry of the dispenser in order to
be connected.
It is noted that to have a dispensing system which is a 100% lock
out of competitors, a Flair bottle is to be used. In this case the
dispenser does not have to vent a Flair system, or a closed bag
within a bag, or container within a container, system needs no
venting (and no headspace in the inner container), and the bottle
cannot be refilled by drilling a hole in the bottle wall. Any
tampering disables the dispensing system.
FIG. 18 illustrates lock out systems for underpressure sprayers. In
a lock out for under pressure, the inlet valve can be normally open
in the output direction of the bottle. The passage way to the
bottle is closed during a compression stroke or when refilling is
attempted. Removing the valve disables the use of the bottle, since
the valve also acts like the inlet valve of the pump. The passage
way to the dispenser is open when the valve rests against the upper
valve seat when liquid enters the pump by under pressure. The upper
valve seat has openings, providing the passage of liquid. There is
a `Key` interface, a set compatible interface features between lock
out and dispensing head, which is customer dedicated.
FIGS. 18A, 18B, 18C, 18D, 18E, 18F and 18G illustrate exemplary key
parameters that can be varied to create user specific lock out
keys. For example, working with various heights and diameters, and
rib geometries, as shown in FIG. 18A, heights h3 and h4 can be used
to lock a custom bottle to a custom lock out key. Moreover,
diameter d1, heights h1, h2, and rib feature geometry can be used
to lock a dispense head to a custom lock system. The dispenser has
to be fitted with matching geometries. For example, when the rib
features of the lock out and contra rib features on the dispenser
do not correspond, the combination of bottle and dispensing head
cannot be made. Thus, a dispenser geometry matching height h1 of
example lock out key B cannot fit to height h1 of example lock out
key A. As well, a dispenser geometry matching diameter d1 of
example lock out key A cannot fit to diameter d1 of example lock
out key B. In exemplary embodiments of the present invention, the
sprayer manufacturer can own all such keys and variations, and
assign/license to a set of customers or distributors a particular
field of use specific to one lock out key. Thus the manufacturer
can control which bottles can interoperate with which sprayer
heads. Similarly, FIG. 19 illustrates a lock out that can be used
with an exemplary sprayer according to the present invention. As
shown, there is a `Key` interface, i.e., a set of compatible
interface features between lock out interface on bottle and
dispensing head, which is customer dedicated. As noted, these can
include a blocking geometry, a certain diameter, and a certain
depth.
FIGS. 20A and 20B illustrate a lock out system for an overpressure
system, where the Flair bottle (bag within a bag, or bottle within
a bottle system) is actively pressurized between the layers to
squeeze out the liquid or product in the inner layer. Such an
overpressure system is disclosed, for example, in U.S. patent
application Ser. No. 13/467,971, filed on May 9, 2012. As shown, In
a lock out for over pressure, the inlet valve is normally closes in
inlet and outlet direction. There is a `Key` interface, a set
compatible interface features between lock out and dispensing head,
which is customer dedicated.
The passage way to the bottle is closed during a compression stroke
or when refilling is attempted. Removing the valve disables the use
of the bottle, since the valve also acts like the inlet valve of
the pump. When the bottle is disconnected from the dispenser, the
valve is pushed to close by the liquid pressure in the bottle.
Liquid will not leave the bottle. When bottle and dispenser are
connected, a protrusion part of the dispenser needs to hold the
valve in intermediate position it not touching both seat valves.
When the pump performs a compression stroke, the valve is pushed on
the lower valve seat, closing the passage way to the bottle. During
the recovery stroke of the pump, liquid can enter the pump, because
the protrusion prevents the valve to close on the upper valve
seat.
Flairosol D'Lite
FIGS. 21-33 illustrate an exemplary "Flairosol D'Lite" sprayer
according to exemplary embodiments of the present invention. FIG.
21 provides exemplary materials for the sprayer, and FIGS. 22-32
highlight each of these in detail. FIG. 33 provides exemplary
dimensions of such a sprayer.
Features/Objectives
Flairosol D'Lite has certain features, with defined objectives, as
follows:
1. Buffer
No metal, all plastic. Store and release the overshoot of liquid in
order to get a continuous and constant output. This technology
gives more possibilities to adjust the Flairosol to the customer
application, when necessary.
2. Prime/Over Pressure Valve
Remove air out of the pump during priming, to avoid no or to late
priming, due to the normally closed valve. When the internal
pressure increases too much, the valve will release this
pressure.
3. Dome Valve Configuration
Obtain greater control of the dome valve mechanical behavior and
hysteresis.
Flairosol D'Lite Technological Features
FIGS. 34-40, next described, illustrate various technological
advances of a Flairosol D'Lite type sprayer. With reference to FIG.
34, a gas loaded buffer can be used. The buffer pressure is set by
the size of the buffer bag and the pressure of the gas inside the
bag. As shown in FIG. 35, the buffer is placed inside the piston.
This improves compactness, the liquid travels in a straight upwards
direction which helps to prevent entrapment of air, and one or more
bypass channels are made to ensure the flow of liquid around the
buffer. The buffering volume is set by the size of the buffer bag.
As shown in FIG. 36, when the piston moves down: liquid is pushed
to the nozzle. The overshoot of liquid not leaving the nozzle is
stored by compression of the gas loaded buffer. When the piston
moves up: the gas loaded buffer pressure pushes out the stored
liquid
FIGS. 37-39 illustrate a novel Prime-Overpressure valve. When
priming, the valve is mechanically opened by the piston. When the
piston reaches the end of the stroke, it mechanically forces the
normally closed Prime-Overpressure Valve to open. Air escapes into
the bottle and the engine primes. FIG. 38 shows the sealing
surfaces of the valve. Finally, FIG. 39 Priming the DuO1 Engine:
illustrates in detail its operation.
Prime issue with DuO1 Engine: When the piston 39B moves down it
compresses air within the system and the air wants to get passed
the normally closed outlet valve 39A. When the air pressure created
is not high enough, the outlet valve is not opened and the engine
does not work. The Prime--Overpressure Valve 39C makes sure the
engine primes.
Pressure build up issue (DuO1 Engine Continuous): When trigger
frequency and speed is high, the internal pressure could be build
up to a critical level. If this level is reached, the pressure
needs to be released. The Prime-Overpressure Valve 39C acts as an
overpressure valve as well.
Novel Dome Valve
FIG. 40 illustrates the use of a novel all plastic binary dome
valve. This pre-compression valve was developed to get a more
"snappy" response on changes in pressure. I.e., digital opening and
closing of this valve, without drips or bigger droplets in the
spray, which improves the nozzle performance. FIG. 40 shows where
the exemplary dome valve is placed within an exemplary DuO1 engine
or application.
FIGS. 41-47 present details of the novel dome valve. As noted in
FIG. 41, the main inventive goal was to create a dome valve having
a more binary behaviour. I.e., a more instantaneous opening and
closing of the dome with as little as possible differences in these
pressures (small hysteresis). For this purpose a dome valve was
created which interacts with a flexible seal. FIGS. 41 and 42 show
six snapshots of the dome valve in operation. These are as follows:
A. Dome valve and dome seat at default. The dome seat seal rests
against the dome valve with pre-tension; B. Pressure deforms the
dome valve. The seal of the dome seat flexes and still rests
against the dome valve; C. The dome valve deforms even more. The
seal valve has flexed to default position and no longer rests
against the dome valve. An opening between seal and dome valve is
created; D. When the pressure decreases, the dome valve swiftly
deforms back again touching the seal. Dispensing stops
instantaneously; E. Dome valve and dome seat at default. The dome
seat seal rest s against the dome valve with pre-tension; and F.
The dome valve diameter is equal or larger than the seal diameter.
A larger the difference increases the hysteresis, the opening
pressure will be higher than the closing pressure of the dome
valve.
As shown in FIG. 43, the dome and seal can be changed in order to
adapt or modify properties such as the opening and closing pressure
and flow. Changes made can be for example the wall thickness,
diameter, material, height, curviness (convex, flat, concave). The
material of the dome valve is ideally a semi-crystalline plastic
such as a PP or PE grade. This suitable for a wider range of
liquids. If the dome needs specific properties such as a higher
flexible modulus, other materials can be used such as POM grades.
This limits compatibility with liquids, bleach for instance is not
compatible with POM. Various shapes, sizes and executions of the
dome valve can exist, such as are shown in FIG. 43, for example. In
these examples, dimensions are merely exemplary.
FIG. 44 depicts a graph and two load cases for an exemplary dome
valve. The graph shows the displacement of the point of the dome
which is in contact with the seal. There are two possible load
cases:
Case 1--Closed situation where only part of the dome is pressurized
and there is a pressure difference over the seal (solid blue line
(initially upper line) in graph)
Case 2--Open situation where the complete dome is pressurized and
there is no pressure difference over the seal (solid green line
(initially lower line that crosses upper line at 0.4 Mpa) in
graph). The dashed blue line (horizontal line at displacement=0.2
mm) is the position of the seal in the "open" situation. FIG. 45
shows the graph of FIG. 44 more magnified.
With reference to the graph of FIG. 45, there are various
operational states of the valve:
A-A' The seal is pre-tensioned by moving the seal 0.2 mm relative
to the dome;
A'-B Pressure buildup gives a displacement of the dome accompanied
with the seal up to the point B. At this point the contact force
between the dome and the seal becomes zero and the valve opens;
B-C When the valve is open the behaviour of the dome changes due to
the fact that the seal is no longer pushing against the dome and
the pressurized section on the dome has become larger. The seal
which is no longer pressurized will go back to its neutral position
at 0.2 mm while the dome jumps to 0.62 mm. This gives a sudden
opening of 0.42 mm over a theoretic infinitesimal small pressure
step. This binary behaviour is necessary to make sure that the
pressure drop over the valve is small enough to have a negligible
effect on the flow through the nozzle; C-D When the pressure
increases further the displacement of the dome will increase. (this
can be limited by establishing a contact between the dome and
another part); D-E When the pressure decreases the dome will become
instable at point E. At this point the distance between the seal
and the dome is still 0.35-0.2=0.15 mm. This opening is necessary
to make sure that the pressure drop over the valve is small enough
to have a negligible effect on the flow through the nozzle; E-F Due
to the instability the displacement of the dome will decrease
instantaneously and the seal (in neutral position) comes into
contact with the dome at point "F". The neutral position of the
seal has to be between point "E" and "X" to ensure the
functionality of the seal;
F-G When the seal is in contact with the dome the "closed"
situation is established and the seal will accompany the dome to
point G. This will happen instantaneously as well; and
G-H Further decrease in pressure will result in gradual decrease in
displacement.
FIG. 46 illustrates the dome shape and configuration during some of
the above-identified operational states.
Finally, FIG. 47 illustrates how in time the pre-stresses in the
seal and dome will relax. This will particularly change the
"closed" behaviour. In the graph presented in FIG. 47 the effect of
a 50% relaxation is presented. It shows that the valve will
continue to function as described in the previous slides.
Gas Buffer Technology
FIGS. 48-65 illustrate exemplary gas buffers that can be used in
exemplary embodiments of the present invention, as well as
exemplary methods of manufacturing them. FIGS. 66-67 illustrate
alternate manufacturing methods. With reference to FIG. 48, the
buffer can be made from a multi-layer tube containing for example;
PE, EVOH, or Yparex. It is pressurized by filling with a gas such
as, for example, air, nitrogen or other gasses. The multi-layer is
needed to provide the desired properties like; The ability to be
welded, Maintaining flexibility so all energy is stored and
released by the enclosed compressed gas, Blocking the gas from
leaving the buffer and therefore maintaining the pressure over
time, and Chemical resistance to the liquid dispensed. A gas buffer
can have, for example, an inner tube. The difference between the
inner tube outer diameter and the buffer tube inner diameter is
related to the buffer capacity. The greater the difference, the
more the capacity. In theory, the external pressure applied to the
could increase to a level in which the buffer would collapse to an
extend it fails. A tube with open ends can be placed in the buffer
to prevent the collapse which leads to failure. This will limit the
extend to which the buffer can collapse when a external pressure is
applied
As shown in FIG. 49, the buffer is an accumulator to store energy.
In a gas buffer, the gas temporarily stores the energy delivered by
the liquid pressure. The pressures are equalized. This energy is
returned when the external liquid pressure is less than the
internal pressure of the gas buffer. As shown in the schematics of
FIG. 49, in a default buffer position: The buffer tube is filled
with a gas having a pressure of e.g. 4 bar. The gas buffer housing
retains the gas buffer tube from gradually expanding by the
internal gas pressure. In a stored energy state: by pressure an
amount of liquid has entered the gas buffer housing. The liquid
pressure compresses the gas in the gas buffer tube and therefore
storing energy and equalizing the pressure. The external liquid
pressure is equal to the internal gas pressure. In a releasing
energy state: When the external pressure applied by the liquid is
decreases, the gas pressure returns the energy. The liquid is
displaced by the expanding gas. As long as the external liquid
pressure is less than the internal gas pressure, the gas keeps
expanding until the buffer has returned to its default position and
therefore default pressure.
As shown in FIG. 50, besides the gas buffer being made with an
multi-layer extruded tube, it can also be made in alternative ways,
such as, for example: buffers made from single or multi-layer foil,
welded to become a buffer bag which can be filled by a gas. The
foil can, for example, be a laminate comprising various layers,
each layer being a specific material with specific properties. For
example, to have better chemical resistance, better barrier
properties. With laminates, almost all materials can be used.
Buffers can, for example, be made with blow molding techniques like
extrusion blow molding, one stage blow mold processes, and in mold
stretch blow molding. FIG. 51 illustrates alternate techniques by
which gas buffers can be made, for example, and FIG. 52 illustrates
use of a dispenser using gas buffer technology. FIG. 51 thus shows
a buffer made by injection molding techniques. For example, a
buffer made by welding a bag in a bag. First, a single layer
extruded tube is filled with gas and welded similar to the
multi-layer tube. Then, the single layer welded is inserted in a
second single layer tube or bag, and welding is performed to close.
Thus, the buffer may be made, for example, by injection molding
techniques. The welding techniques can include, for example,
ultrasonic welding, laser welding, hot stamp welding, gluing,
etc.
FIGS. 53-65 illustrate exemplary manufacturing techniques for gas
buffers. In particular, FIG. 53 lays out a sequence that can be
implemented on an automated or semi-automated machine. With
reference thereto, this sequence includes 12 steps: (1) Feed the
tube to the manufacturing line; (2) Press to close one end of the
tube; (3) Weld one end of the tube (=Weld 1); (4) Cool down weld;
(5) Place injection needle; (6) Press to seal needle and inject air
pressure; (7) Press to close tube; (8) Remove the needle; (9) Weld
to seal the tube (=Weld 2); (10) Cool down weld; (11) Check
pressure; and (12) Check dimensions.
FIG. 54 depicts an exemplary machine for manufacturing a gas buffer
using essentially the sequence of FIG. 54, and FIG. 55 presents an
overview and key part list for the exemplary machine. There is, for
example, an Upper welding head 5501, a Lower welding head 5502, a
Lower clamp left 5503, an Upper clamp left 5504, an Upper clamp
right 5505, a Lower clamp right 5506, a Needle 5507, Cooling clamps
5508 and a pressurized gas 5509.
FIGS. 56-65 set forth exemplary steps in creating a gas buffer
using the exemplary apparatus of FIG. 54, as follows:
FIG. 56 shows Step 1, enter the tube to weld the first end. FIG. 57
shows Step 2, after the upper and lower clamp left closes, the
upper and lower welding heads close, welding is in progress. FIG.
58 shows Step 3, where after the upper and lower welding heads
open, welding stops, and cooling clamps comes in and squeezes
around the weld. FIG. 59 shows Step 4, where after cooling the
tube, the cooling clamps open, and the buffer tube with one side
welded can be removed. FIG. 60 shows Step 5, where after the buffer
with one side welded is placed with the opposite open side towards
the needle, the open side of the buffer tube is pushed over the
needle. FIG. 61 shows Step 6, where after the upper and lower clamp
on the right closes, the buffer tube around the needle is sealed,
and gas enters the buffer through the needle. FIG. 62 depicts Step
7, where after the upper and lower clamp on the left closes, the
buffer tube is at pressure when the needle retracts, and the right
clamps open again. FIG. 63 shows Step 8, where the 2nd side is
thermally welded and the upper and lower welding heads close,
welding is in progress and the 2nd weld is made. FIG. 64 shows Step
9 where the upper and lower welding heads open, the welding stops
and the cooling clamps comes in and squeezes around the weld.
Finally, FIG. 65 shows Step 10, where after cooling the tube, the
cooling clamps open, and the welded buffer can be removed.
Alternate Gas Buffer Fabrication
As noted, FIGS. 66A-67 illustrate an exemplary alternate gas buffer
manufacturing technique. With reference to FIG. 66A, one can create
the gas buffer by beginning with a co-extruded tube on a reel. The
pressure in the tube can be, for example, 3.5 barg. The tube can be
made of, for example, polyethylene, polypropylene, polyamides,
silicone, AVOH, a sandwich of layers of aluminum, polyester and
polyethylene, to name a few possibilities, depending upon the gas
buffer properties needed, and the types of chemical resistance
needed, in various sprayer devices. The end of the tube can be
pinched or welded and cut, and the sealed bag can be quickly placed
into the buffer chamber, as shown in FIG. 66E. Next, as shown at
FIG. 66B, the sealed bag is a bit smaller that the buffer chamber,
but the bag will expand, as shown in FIG. 66C. This will cause the
material in the bag to creep until it hits the buffer chamber wall.
As a result of this expansion, the pressure inside the bag is now
dropped to the pressure needed, for example, approximately 2.5
barg. Finally, the buffer chamber can be capped to hold the buffer
in place and otherwise seal the chamber as shown in FIG. 66D.
FIG. 67 shows yet another method for assembling a gas bag-type
buffer chamber. With reference to FIG. 67, at stage 1 there can be
provided a co-extruded tube inserted into a pressure chamber. The
pressure in the chamber can be, for example, 3.5 barg. It is within
the pressure chamber that the co-extruded tube is welded on both
ends at stage 2, and then, at stage 3, transported, still under
pressure, to a second pressure chamber whose internal pressure is
approximately 5 barg, for example, (or some value greater than the
pressure in the first chamber). Due to the higher pressure in this
second pressure chamber the bag shrinks at stage 4. At stage 5, the
bag is pushed from the second pressure chamber into the buffer
chamber, and at stage 6 the bag expands until it hits the wall of
the buffer chamber, thereby losing internal pressure and dropping
from 5 barg to 3.5 barg which is the desired final pressure. At
this point the buffer chamber can be capped as shown at stage 7.
This results in a 3.5 barg gas buffer, for example, matching the
initial pressure of the first pressure chamber.
Returning now to FIGS. 52A and 52B, this shows how a gas buffer can
operate in practice. With reference thereto, there is a gas buffer
with an exemplary 2.5 barg in its bag, as shown as the end result
of the process depicted in FIG. 66, i.e., FIG. 66D. In FIG. 54A,
liquid is pumped into the buffer, in particular in between the
buffer housing and the buffer bag. The air in the bag is thus
further compressed due to the pressure of the liquid, creating a
higher pressure than the original 2.5 barg. With reference to FIG.
52B, when the additional liquid under pressure ceases to be pumped
into the buffer (i.e., the downstroke of the piston has completed),
the liquid in the buffer is now pushed out of the buffer because
the buffer bag naturally expands until it once again hits the wall
of the buffer housing. In this manner the energy stored in
compressing the bag to continue the outflow of liquid through the
sprayer head in between strokes, thus offering continuous
spray.
Duo1 Pump Engine for Various Applications:
In exemplary embodiments of the present invention, the DuO1 Pump
engine can be used in all kind of dispensing applications, such as,
for example, floormops, window washers, sprayers, and applicators.
The DuO1 Pump engine can be used in a wide pressure-range of
dispensing applications, from low to high pressures. The DuO1 Pump
engine can be made in all kind of types, configurations and
combinations of configurations and materials, adjusted to specific
needs of each application.
For example, such as multiple pumps, dimensions of the pump or
pumps, length of the stroke, nozzle or multiple nozzles, position
of the nozzles, direct stop, continuous, continuous-stop, low
pressure, and high pressure.
Multiple Pumps in Parallel to Increase Output
FIGS. 68A through 68D show how multiple pumps can be used with
common inlet line and a common outlet or output line to increase
output using a DuO1 type system. This is especially useful in
contexts such as a "Flairomop" device, described below, and shown
in FIG. 68A. As shown in FIGS. 68B and 68D, there can be a liquid
container 6801 with container venting 6802 Container venting 6802
is not needed, of course, if a Flair bottle is used, because the
venting in a Flair bottle is integrated in the container/bottle,
and no head space is necessary to be maintained above the liquid in
the liquid container. There can also be a spring 6803, a pusher
68044, pistons 6805, piston housing 6806, non-return valve inlet
piston 6807, a separate inlet valve 6807A, which is optional, a
non-return valve inlet to the nozzle or buffer 6808, and a separate
valve inlet to the nozzle buffer 6808A. It is noted that inlet
valve 6807A, when used, is connected to the container bottle and
outlet line 6808A is connected to the buffer, and from there to the
nozzle. As can be seen in FIG. 68, one can use one, two, three,
four or more pistons and piston chambers in parallel, all of which
may be, for example, simultaneously actuated by pusher 6804.
Although to achieve similar results one could simply increase the
size of the piston chamber, using multiple chambers in parallel
allows for a standard unit to be manufactured, and increase of size
simply achieved by adding units.
Flairomop--Floor Cleaner Using DuO1 Sprayer Technology
Finally, a novel device for cleaning floors and the like is next
described. This device utilizes the novel new generation sprayer
technologies described above, where the sprayer is essentially
mounted upside down so as to spray on a floor. These devices are
known as a "Flairomop" or a "FlairoWasher", for example. They
operate in similar fashion to the upright buffered sprayers
described above,
FIGS. 69A through 69E illustrate details of nozzle placement an
exemplary Flairomop. As shown in FIG. 69B, the nozzles can be
provided above the floor plate, or at the bottom of the floor
plate, as shown in FIGS. 69C, 69D and 69E. If provided on the floor
plate, for example, they can have either a single nozzle
configuration as shown in FIG. 69C, a double nozzle configuration
as shown in FIG. 69D, or multiple nozzles, such as is shown in FIG.
69E. A Flairomop can use a sprayer, of the various types described
above, with various buffer types.
Thus, in exemplary embodiments of the present invention, a
Flairomop can have three basic types: (i) small fanspray-nozzle,
high pressure, useable with all buffers; (ii) small
fanspray-nozzle, high pressure, useable with all buffers, direct
action; and (iii) low pressure useable with all buffers.
General Features
General features of an exemplary Flairomop can include, for
example, an output greater than 3 cc, the ability to produce a fan
spray, the ability to produce all types of spray and foam
functions, the use of pre-compression with a normally closed front
or outlet valve, the use of a Flair container holding between 250
and 1000 cc's, no blockage of opening due to drying in of liquid,
broad chemical resistance to detergents solvents, olive oil etc., a
low trigger force required to actuate. Optionally, for example, the
Flair bottle can also be used with a lock-out mechanism, as
described above.
Flairosol Based Flairomop
FIG. 70 illustrates an exemplary Flairomop using a standard
Flairosol sprayer mechanism. This is essentially a spring buffered
non-inline sprayer system built onto an existing Flairomop
prototype. As shown in FIG. 70(a), there can be a fanspray nozzle,
and liquid can be pushed into the integrated buffer. After
triggering, the spring will push back the buffer piston to dispense
the contents of the buffer, as described above. Thus, there is a
connector, a piston closure, a standard Flairosol sprayer head, a
Flairosol integrated buffer and a Flair bottle. As shown in FIG.
70(b), by triggering the handle at the shaft, the piston can be
pushed downwards and the spring biasing the piston will push it
back upwards, making it available once again for a user. In this
particular example, using a 16 mm boring and a 21 mm stroke length
for the piston chamber, about 4 cc of liquid can be moved per
stroke. Of this, a certain amount is pushed through the nozzle, but
the remaining portion goes into the integrated buffer.
High Pressure Continuous Spray Single Nozzle
FIGS. 71 and 72, show an exemplary embodiment of a Flairomop
designed to produce a high pressure continuous spray. As shown in
FIG. 71, when a user triggers, the complete volume of the piston
chamber will be dispensed. Because the output of the piston chamber
is bigger than that which the nozzles can handle, the remainder of
the liquid from the piston chamber will be stored in the buffer for
later dispensing. There is no direct stop, however, as in the case
of a direct action sprayer ("direct stop" and "direct action" are
used inter-changeably in this disclosure, for a sprayer that ceases
spraying immediately upon a user letting go of the trigger), and
dispensing will stop as the buffer is emptied and the liquid falls
below the set pressure of pre-compression valve 8, which can be,
for example, between 2-6 barg, such as, for example, say 2.2 barg
in some embodiments.
FIG. 72A is a schematic diagram of the system of FIG. 71. With
reference thereto, there is shown a liquid container 7701, optional
container venting 7702 for use with non-Flair bottles, piston 7703,
piston housing 7704, and non-return inlet valve for the piston
7705, non-return inlet valve for the buffer 7706, buffer 7707,
pre-compression valve 7708 and nozzle 7709. It is noted that this
embodiment uses a standard separate piston, but, as noted above, a
novel stretched piston could also be used. As shown in FIG. 72A,
this is a high pressure system with a liquid buffer. As the piston
moves upwards, liquid is drawn from the liquid container due to the
under-pressure which is created. The container either needs to have
air venting 2, or needs to use a Flair type bottle, as described
above, which requires no venting.
Next, by a user pushing the piston downwards the liquid is forced
to go to the nozzle, or multiple nozzles, as shown in FIG. 69
above. Because of the restriction of the nozzles as far as handling
volumes of liquid per unit of time, a certain portion of the liquid
will go into the buffer, such as, for example, 2/3 of the liquid,
and generally always more than half of the liquid in the piston
chamber, the exact fraction depending upon the piston chamber
volume and diameter, and the restriction in the nozzle(s). The
buffer will then be filled with liquid and the pressure in the
buffer will increase. As the piston reaches the end of its
downstroke, the liquid collected in the buffer will then be
dispensed through the nozzle(s) as there is no longer any liquid
being pushed out of the piston chamber. As shown in FIGS. 72B
through 72E, the buffer can be any of the various types described
above such as, for example, spring loaded, spring loaded in-line,
elasticity material, or gas loaded. In preferred exemplary
embodiments, a gas loaded buffer can be used. Additionally, gas
buffers can be used that hold the liquid on the outside of a
central gas filled bag, or for example, a liquid can be pumped in
the interior of a surrounding gas shell, in the nature, shape wise,
of the elasticity material buffer shown in FIG. 71.
High Pressure Continuous Spray Multiple Nozzle
In a manner wholly analogous to FIGS. 71 and 72, FIGS. 73 and 74
show an exemplary high pressure continuous spray Flairomop
embodiment with two nozzles on the floor plate, as opposed to one
nozzle provided on the handle, under the buffer, as shown in FIG.
71B. In all other respects it is identical to the exemplary
embodiment of FIGS. 71 and 72. The continuous spray is achieved by
use of the buffer, as described above. As shown above in FIG. 1, as
long as the buffer volume v2 is at least as large as the volume of
liquid sent to it in each stroke v1, the buffer can then dispense
such excess (shown as top of curve above upper pressure line Pmax,
and then moved to fill in between pumping strokes, in far right
image of FIG. 1) v1 between strokes. The number of strokes per
minute necessary to maintain continuous spray is thus a function of
the fraction of the liquid in the piston chamber sent to the buffer
each stroke, the type of nozzle, and the opening pressure in the
pre-compression outlet valve, and can be adjusted using those
parameters, for various systems as desired.
As shown in FIGS. 73A and 73B, once a user has triggered, the
complete volume of the piston will be dispensed. Because the output
of the piston is bigger than that which the nozzle(s) can handle to
dispense, the rest of the liquid will be stored in the buffer, and
will be dispensed later. There is no direct stop in this
embodiment. The dispensing will thus stop as the buffer empties at
the set pressure of the pre-compression valve.
As shown in FIG. 74A, this is a high pressure system with liquid
buffer.
By the piston movement upwards liquid is taken from the liquid
container due to the under pressure which is created. The container
needs an air venting or Flair (bag within a bag) bottle.
By pushing the piston downwards the liquid is forced to go to the
(multiple) nozzle(s) AND due to the nozzle output restriction, into
the buffer. The buffer will be filled with liquid and the pressure
in the buffer will increase.
As the piston is at the end of its stroke downwards, the liquid
collected in the buffer will be dispensed through the nozzle(s).
With Flairosol (or other Flair type systems) venting is not
necessary because the venting is integrated in the
container/bottle. Venting is needed when a standard
container/bottle is used.
High Pressure Direct Action
FIGS. 75 and 76 illustrate an exemplary high pressure direct action
Flairomop device with one nozzle. In all other respects it is
identical to that shown in FIGS. 71 and 72 except that, being a
"direct action" type, there is no non-return inlet valve for the
buffer keeping liquid form escaping the buffer back to the piston
chamber. Thus, when a user releases the trigger, there is a direct
stop: liquid will flow back into the piston chamber, thus stopping
the spray.
As shown in FIG. 75, once a user has triggered, the complete volume
of the piston will be dispensed as long as the user holds the
trigger. Because the output of the piston is bigger than that which
the nozzle(s) can handle to dispense, the rest of the liquid will
be stored in the buffer, and will be dispensed later. There is a
direct stop in this embodiment once the trigger is released. Liquid
will flow back into the piston chamber (no non-return valve inlet
buffer).
As shown in FIG. 76, this is a high pressure system DIRECT ACTION
with liquid buffer. By the piston movement upwards liquid is taken
from the liquid container due to the under pressure which is
created. The container needs an air venting or Flair (bag within a
bag) bottle.
By pushing the piston downwards the liquid is forced to go to the
(multiple) nozzle(s) AND due to the nozzle output restriction, into
the buffer. The buffer will be filled with liquid and the pressure
in the buffer will increase.
As the piston is at the end of its stroke downwards, the liquid
collected in the buffer will be dispensed through the nozzle(s).
With Flairosol (or other Flair type systems) venting is not
necessary because the venting is integrated in the
container/bottle. Venting is needed when a standard
container/bottle is used.
Low Pressure Flairomop
Finally, FIGS. 77 and 78 illustrate an alternate exemplary
embodiment of a Flairomop, one that operates at low pressure. In
this exemplary embodiment there are two nozzles 7709 on the floor
plate, as described above. There is also added a restrictor 7707 to
control the amount of output that can be sent through the nozzle
path each stroke. The main differences between the lower pressure
Flairomop of FIGS. 77 and 78 and the high pressure versions of
FIGS. 71-76 is the opening pressure of pre-compression valve 7708.
Because the size of the piston 7703, as well as the piston housing
7704, are increased in this exemplary embodiment, the operating
pressure must be lowered in order to reduce the necessary
triggering force. This results in greater output with a lower force
required for each stroke, which is useful for people, such as, for
example, older persons, who wish to clean a floor or other surface
and do not have the strength to really push hard many strokes per
minute. Once a user has triggered, the complete volume of the
piston 7703 will be dispensed. However, because the output of the
piston chamber 7704 is by design larger than that which the nozzles
7709 can handle, the rest of the liquid will be stored in the
buffer 7706 for later dispensing. In contrast to some of the
embodiments described above, such as are shown in FIGS. 75-76,
there is no direct stop as the trigger is released. Thus, there is
a non-return inlet valve 7705 for the buffer, which causes the
buffer 7706 to dispense its contents until the pressure in the
buffer 7706 drops below that of the opening pressure of
pre-compression valve 7708, even after the user releases the
trigger. Alternatively, a direct action embodiment of this version
could also be made, which allows a user to stop the dispensing form
the buffer immediately upon releasing the trigger. Although this
gives greater control, it requires holding the trigger down
(against the force of the spring) at all times dispensing is
desired, which is often less convenient. FIG. 78, analogous to the
other schematics described above, is a schematic for the exemplary
embodiment of FIG. 77. Thus, shown in FIG. 78 are liquid container
7701, container venting 7702, piston 7703, piston housing 7704,
non-return valve inlet piston 7705, non-return valve inlet buffer
7705A, buffer 7706, restrictor 7707, pre-compression valve 7708 and
nozzles 7709.
As shown in FIG. 78, this is a low pressure system with liquid
buffer.
By the piston movement upwards, liquid is taken from the liquid
container due to the under pressure which is created.
The container needs an air venting or Flair bottle.
By pushing the piston downwards the liquid is forced to go to the
(multiple) nozzle(s) AND due to the nozzle output restriction, into
the buffer.
The buffer will thus be filled with liquid and the pressure in the
buffer will increase.
As the piston is at the end of its stroke downwards, the liquid
collected in the buffer will be dispensed through the nozzle(s).
With Flairosol (bag in a bag technology), venting is not necessary
because the venting is integrated in the container/bottle. Venting
is needed when a standard container/bottle is used.
Continuous Stop Engine
FIGS. 79-85, next described, illustrate a continuous stop engine.
Following that, FIGS. 86-90 illustrate an improved stopping
feature. Finally, FIGS. 91-92 illustrate a further improvement to
the stopping feature.
A continuous stop engine allows for continuous spray, as described
above, but then immediate cessation of spray when desired by a
user. This combines the benefits of a continuous spray engine with
direct action. With reference to FIG. 79, for a high/low pressure
system with liquid buffer:
Continuous:
When the piston moves up, liquid is taken from the container and
enters the piston chamber. For this the container needs an air vent
or Flair bottle. When pushing the piston downwards the liquid is
forced to go to the (multiple) nozzle(s) and all liquid which
cannot leave the nozzles is stored into the buffer. The buffer
applies pressure to the liquid stored. When all of the liquid in
the piston chamber is dispensed, the liquid stored in the buffer is
dispensed through the nozzle(s), even when the piston moves up
again to take in liquid from the container.
Stop:
When the release valve is activated, liquid stored in the buffer
flows back into the container. This action immediately stops
dispensing.
The schematic of FIG. 79, due to its detail, has its own specific
index numbering system, different than any other figure hereof,
although there is some overlap. With reference to FIG. 79, there is
shown a container 7901, which could be a Flair container, a buffer
7902, a spring 7903, a piston 7904, an inlet valve 7905, a one-way
valve 7906, a pre-compression valve 7907, a release valve 7908, a
container air vent 7909, a filter 7910 and a floor plate 7911.
FIG. 80 illustrates exemplary parts: a piston 8101, an inlet valve
8102, a one way valve 8103, a buffer 81, a pre-compression valve
8105, a release valve 81 and a release valve actuator 8107. Index
numbers for FIGS. 80 through 86 are specific to the "continuous
stop engine" embodiment, as this embodiment has its own set of
elements.
FIGS. 81-85 illustrate five steps in operation of the exemplary
continuous stop engine, as follows:
FIG. 81:
1. Take in Liquid from Container
The piston moves up all the way. Liquid from the container is taken
into the piston chamber past the inlet valve (8102). The one way
valve (8103) closed off the passage between the piston chamber and
the buffer. The release valve (8106) is open.
FIG. 82:
2. *Piston Moves Down
The inlet valve (8102) closes. Liquid from piston chamber is pushed
past the one way valve (8103). Liquid travels via the buffer (8104)
and past the pre-compression valve (8105) towards the nozzle(s).
The overflow of liquid which cannot leave the nozzles is stored in
the buffer. The release valve activator (8107) can move down and
the release valve (8106) is closed.
FIG. 83
3. Piston Moves Up
The piston moves up, but not all the way. The release valve
activator (8107) is not touched. Liquid from the container is taken
into the piston chamber past the inlet valve (8102). The one way
valve (8103) closes of the passage between the piston chamber and
the buffer. The overflow of liquid stored in the buffer passes the
outlet valve.
FIG. 84
4. Continuous Output When the piston moves up and down in given
area, without touching the release valve activator (8107), a
continuous output is generated.
FIG. 85
5. Stop
The piston moved up all the way. The release valve activator (8107)
is pushed upwards
The release valve opens (8106). The liquid stored in the buffer
flows back to the container and the pre-compression valve (8105)
closes, and dispensing stops immediately.
FIGS. 86-90 illustrate a method to improve the stopping feature,
based on relocating the valves. In the 2 mm for releasing the
accumulator, another valve can also be actuated. This also improves
vertical assembly. As shown in FIG. 86, there can be a home or 0 mm
position, a 2 mm position, and a 17 mm position. Once the trigger
moves to the 2 mm position, there is a temporary stop, via a
trigger blocking feature. If it is engaged, the trigger cannot
return to the home position, as the trigger is now blocked, but the
trigger is free to travel from the 2 mm to the 17 mm position
repeatedly. However, once the blocking is disabled or released, the
trigger can return to zero (home position) and activate the valve
to redirect the flow out of the buffer, thus immediately stopping
the spray. Such a system is implemented in the exemplary embodiment
shown in FIG. 87. Thus, with reference to FIG. 87, the pump is
actuated by a handle and trigger. The push rod is connected to the
pump piston. The full stroke of the trigger equals a push rod
travel of 15+2 mm. When the trigger is pulled from 0 mm to 2 mm, at
2 mm a feature automatically blocks the trigger from returning to 0
mm. The return valve is now closed. However, the trigger is able to
travel from 2 mm to 17 mm. Within this zone actuating will give
spray performance, prolonged or continuous depending on the
actuation rate of the user. When disabling the blockage of the
trigger, so it can and will return to 0 mm, the return valve can be
opened and the liquid within the buffer can flow back to the
bottle. Dispensing thus stops immediately.
FIGS. 88-90 show how this is implemented within the device:
FIGS. 89A and 89B--Between 0 and 2 mm position: Within this area
the liquid return valve is operated.
In position `0` the spring of the piston lifts up the liquid return
valve 89A opening the passage towards the bottle. By means of a
tumbler the same force opening the liquid return valve, closes the
outlet valve 89B. As soon as the piston is pushed in 2 mm, the
spring of the return valve 89A closes of the passage to the liquid.
The pre-compressed outlet valve 89B is released.
FIGS. 90A and 90B--Between 2 and 17 mm position:
Within this area the output is generated. Since the opening towards
the bottle is closed in position 2 mm, liquid which is displaced by
the piston no longer travel to the bottle but is pushed to the
released outlet valve 90A. The liquid displaced pushes open the
outlet valve. The overflow of liquid is stored in the buffer 90C.
As long as the piston moves between position 2 mm and position 17
mm, a continuous output is created. When the piston moves beyond
position 2 mm towards position `0`, the outlet valve is forced to
close and the liquid return valve is opened. The liquid passes to
the bottle and output is stopped immediately.
A further improvement to the stopping feature is illustrated in
FIGS. 91-92. Here, as shown in FIG. 91A, the operation of the pump
was separated from the operation of the liquid return
valve/pre-compression outlet valve. A cable 91A operates the valve
system 91B, and a push rod activates the pump 91C. As shown in FIG.
91B, the cable is activated by a feature 91D located at the handle.
The push rod 91E operating the pump is activated by pulling the
trigger 91F. This can be implemented, for example, as shown in
FIGS. 92A through 92C, where: (a) upon pulling the cable, the
liquid return valve is force to close, and the pre-compression
outlet valve is released. Upon (b) releasing the cable:
The liquid return valve opens by spring force. Liquid pressure is
let off, because the liquid can return towards the bottle. The same
spring force opening the liquid return valve flips the tumbler and
forces the pre compression outlet valve to close.
Standard DuO1 Sprayers with Buffering
FIGS. 93A-96B illustrate applying the buffering and dome valve
principles described above to standard sprayers, making "DuO1
Sprayers." FIG. 93 illustrate an exemplary direct stop sprayer. As
shown in FIGS. 93A through 93C, the features of the direct stop
sprayer include a classic sprayer like configuration of parts where
no extra part is needed for venting, the piston moves when the user
pumps and there is a static nozzle. A large buffer is needed and
there is a larger travel distance of the trigger compared to
standard sprayers. The long trigger is needed to compensate for the
higher forces required to push liquid a larger piston volume, and
therefore the direct stop sprayer is larger than a standard
conventional sprayer. It is noted in FIG. 93C that no umbrella
valve is used in the direct stop sprayer, and thus, when a user
releases the trigger, liquid can flow from the buffer back into the
piston chamber. This effectively stops all flow as soon as a user
releases the trigger. Thus, a direct stop sprayer allows for
prolonged spraying/foaming even after the downstroke is over, as
long as a user holds the trigger down, and thus holds the piston
chamber closed.
FIG. 94 presents details of an exemplary continuous sprayer
according to exemplary embodiments of the present invention. As
shown in FIGS. 94A and 94B, this sprayer also has a classic
sprayer-like configuration of parts, with no extra part needed for
venting. The piston moves when pumping and there is a static
nozzle. The travel of the trigger is similar to other sprayers and
this is visually similar to a standard sprayer. However, there is
included in the buffer sprayer the umbrella valve as shown in FIG.
94B. This operates as a one-way valve between the piston chamber
and the buffer, such that even when a user releases the trigger, no
liquid can flow from the buffer into the piston chamber. Thus the
liquid continues to flow from the buffer out through the nozzle as
long as the buffer pressure exceeds the opening pressure of the
dome valve.
Other DuO1 Sprayers
FIGS. 95A and 95B illustrate various features of a DuO1 dispenser
with non-inline buffer according to exemplary embodiments of the
present invention. This improves upon Dispensing Technologies'
previous Flairosol technology, as described in U.S. Patent
Application Ser. Nos. 13/068,267 and 13/623,860, now pending, the
disclosures of each of which are hereby incorporated by reference
herein (these describe what may be called "first generation"
Flairosol). With reference to FIG. 95, which presents a perspective
view in 95A and a cutaway cross-sectional view in 95B, there can be
seen a configuration of parts of an exemplary DuO1 device. Although
similar to that of the first generation Flairosol, an extra part is
needed for venting. There is also a static piston where a nozzle
moves up and down while spraying, and there is a larger travel
distance of the trigger compared to a standard sprayer. Finally,
the device is visually different from a standard sprayer. FIGS. 96A
and 96B show various operational states of the DuO1 device of FIGS.
95A and 95B. With reference to FIG. 96A, when the trigger is
released liquid is sucked into the liquid chamber through the inlet
valve. With reference to FIG. 96B, when the trigger is pulled
liquid is pushed past the outlet valve to the nozzle and whatever
liquid cannot be handled by the nozzle (due to the restriction of
the nozzle) such excess liquid is stored in the buffer, as shown.
With reference to FIG. 97A, when the trigger is released by a user
the excess liquid stored in the buffer is then released to the
nozzle, as shown by the white arrow in FIG. 97A. At the same time
the liquid chamber (piston chamber) is filled again in preparation
for a further downstroke as shown in FIG. 96B. This allows for a
continuous spray.
FIG. 97B shows detail of the umbrella valve and the dome valve with
reinforcing spring. To make sure that the DuO1 device always
primes, the valve is mechanically opened when the piston reaches
the end of the stroke; by this means air can be evacuated. So
generally the end of a stroke looks like the configuration of FIG.
97A which is right before the release by a user of the trigger, and
there is some liquid remaining in the piston chamber. However, on
the first stroke which primes the sprayer there is no liquid in the
chamber, and the piston can move all the way up to completely close
the piston chamber, thereby touching the umbrella valve which
thereby pushes upwards and deforms the red dome valve, allowing the
air to escape. By this means the outlet valve is forced open and
the sprayer can be primed.
The above-presented description and figures are intended by way of
example only and are not intended to limit the present invention in
any way except as set forth in the following claims. It is
particularly noted that the persons skilled in the art can readily
combine the various technical aspects of the various exemplary
embodiments described.
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